.     Successfully Implementing Lean Manufacturing Tools, tips and techniques for driving out cost and building a globally-competitive operation   Click here to receive a brochure via email (PDF)   Dear Manager, Competitive global cost pressures and increasing demands from customers are requiring manufacturers to build products faster, better and cheaper. While most plants deliver annual improvements of 3-6% in Key Performance Indicators (KPIs), world-class companies have been able to slash unit costs by a third, quality defects by two-thirds and lead times by up to 90% in just three years through successful implementation of Lean. Unfortunately, most Lean efforts fail to deliver the expected performance gains. Implementation is often haphazard and the technical components (takt time, kanban, etc.) are emphasized over the engagement of people at all levels. And while there is no shortage of books, articles and seminars on Lean, very few address real-world issues and how to avoid the pitfalls. This three-day seminar is jam-packed with practical, proven tips, tools and techniques for building a leaner, more competitive organization. We will cover the Lean tools in depth, but more importantly, we will discuss how to implement them successfully while engaging the entire organization. We will lay the groundwork for those looking to start a Lean initiative, as well as for those who need to retool their current approach. Unlike other Lean seminars that cover the basics and emphasize the amazing results, this session is about the “nuts and bolts” of how to make it work. If a leaner operation is on your agenda, you cannot afford to miss this event. Join us in Chicago on June 9-11, 2008 for a fun and informative three days! If you would like to schedule this program at your facility, please call us at (916) 797-2263. Best wishes in your pursuit of World-Class Manufacturing! Don Penkala President/Seminar Leader For a brief article on Lean Manufacturing, please click here. Top 10 Reasons to Attend 1. We’ll show you how to make Lean self-funding 2. We’ll discuss Lean from a practical perspective 3. You’ll learn how to cut operating costs by 20% or more 4. You’ll learn how to improve flow and cut lead times by 80% 5. You’ll learn how to eliminate unplanned downtime 6. We’ll cover techniques for “mass customization” 7. We’ll discuss the unique issues facing multishift operations 8. You’ll benchmark your performance against the best 9. We’ll move beyond the basics to more advanced Lean concepts 10. You’ll learn from others on the Lean journey   Seminar Outline - Day One 1. A Primer on Lean Becoming globally competitive with Lean The key Lean metrics Performance results from successful implementations Identifying the 10 manufacturing wastes Identifying the 6 manufacturing losses Lean's 10 commandments Push vs. Pull vs. Flow Manufacturing Exercise: Leaning Your Plant: A 20-Point Self-Assessment 2. Lean Implementation Strategy A proven step-by-step implementation process Training requirements to support Lean Staffing strategy to support Lean Developing a Business Case for Lean Exercise: Lean Simulation - Participants will work on an assembly line to test the effectiveness of Push, Pull and Flow Manufacturing concepts. We will then measure the performance of each scenario 3. Value Stream (Process)  Mapping Value-Added Analysis Creating a detailed Value Stream Map Designing a Future State Mapping Material and Information Flows Day Two 4. Making Processes Flow Exercise: Participants will map a value stream in their own operations, identify opportunities to eliminate waste and create a Future State Map to guide improvement efforts Using OEE to achieve global competitiveness 7 steps for successful Cell Design and Implementation Lean scheduling and Mixed-Model Manufacturing Establishing takt time Strategy for reducing changeover time by 70-90% Balancing multishift operations to support Lean 5. Developing an Effective Pull System Rules and requirements for Pull 7 steps to successful Kanban implementation Types of kanbans and when to use them Inventory reduction and Continuous Improvement with Kanban 6. Improving Process Reliability with TPM Process Reliability self-assessment Success measures and Best Practices in Reliability 6 basic elements of TPM In depth: the 7 steps of Autonomous Maintenance Exercise: Operator-Driven Reliability - Group exercise and case study 7. Quality Tools to Support Lean Creating an effective Visual Communication system Bst practices in intershift communications Tools for engaging employees and building morale Successfully implementing 5S Building-in Quality Error-proofing (poka-yoke) Establishing standardized work procedures Building Root Cause Analysis (RCA) capability Exercise: Engaging the entire organization in Continuous Improvement 8. From Lean Manufacturing to Lean Enterprise Lean for Administrative and Office operations Integrating Lean and Six Sigma Sustaining the Gains - Lean Audit Tool Why Lean conversions fail and how to avoid the pitfalls Case examples of successful implementation Exercise: Putting It All Together - Participants develop a step- by-step Lean Action Plan to ensure application of training back at work Who Should Attend? Manufacturing executives, plant/operations managers,shift supervisors and professionals from HR, Quality, Maintenance, Engineering, Training & Development, Logistics & Customer Service will receive excellent value. Date and Location Monday - Wednesday, June 9-11, 2008 in Chicago. Hotel information will be sent with confirmation of registration. Tuition/Registration Successful implementation requires plant-wide support and commitment, so why not train as a team? Standard tuition: $1995 per person Sign up just two people and receive a 15% discount off each enrollment Sign up four and receive a 25% discount To send a larger team, please call us for special pricing To register, please click here. To pay be credit card, please click here. To bring this program to your facility, please click here and tell us what your objectives are and how many people you'd like to participate. Tuition includes the seminar manual (200+ pages), reference materials, continental breakfasts, refreshments and lunches, a free E-zine and a free follow-up telephone consultation following the seminar. Your satisfaction is guaranteed! To ensure a positive learning experience, attendance will be limited so respond early with your paid reservation to guarantee a spot. Payment is due one week prior to the seminar. We cannot issue refunds after this date, but if you need to cancel, you may send a substitute or receive credit towards a future seminar. Please note that there is a $100 processing fee for all cancellations. Hotel information will be sent along with confirmation of registration. Bring This Seminar In-House! Train as a team and limit the time away from work. Build a customized workshop tailored to the needs of your organization Train up to 20 people at a time for a flat tuition fee Work on specific challenges unique to your facility Prior to the workshop, the seminar leader will tour your facility and talk to your people to better understand your unique situation. For more information, please click here or call us at (916) 797-2263.   .